Design, production, and fatigue testing of an optimized structural component made of L-PBF AlSi10Mg

• DOI: 10.1016/j.prostr.2021.12.027
• Publication Date: 2022-01-04T12:43:26Z
• Authors: Federico Uriati; Luca Zambrelli; Gianni Nicoletto; Michele Garibaldi
• Keywords: Component (thermodynamics); Topology optimization; Fatigue limit

Laser Powder Bed Fusion is considered as one of the most innovative manufacturing technologies and has rapidly gained interest in industry because it allows to produce near-net-shape metal components characterized by complex geometry. The structural integrity parts with geometrical characteristics driven optimized lightweight trade-offs should be verified before they are for critical applications sectors such automotive aerospace. In this work a case study presented: topology optimization performed on down-scaled component target definition terms weight stiffness ratio. An integrated design workflow AM part (i.e., from topological process simulation production), ii) actual fabrication an industrial-grade L-PBF system using AlSi10Mg alloy powder iii) qualification fatigue testing parts. material selected AlSi10Mg, typically used field. SLM500 parameters 50 μm layer thickness tested laboratory. Knowledge link between technology-dependent factors strength was determined specific test methodology miniature specimens. anisotropic behavior obtained specimens revealed key role residual stresses as-built AlSi10Mg. Prediction response benefited extensive modeling activities ad-hoc testing.